U.S. patent application number 12/534296 was filed with the patent office on 2011-02-03 for methods and systems for detecting defects in welded structures utilizing pattern matching.
This patent application is currently assigned to GEORGIA TECH RESEARCH CORPORATION. Invention is credited to Renfu Li, Matthew Rogge, Ifeanyi Charles Ume, Tsun-Yen Wu.
Application Number | 20110023609 12/534296 |
Document ID | / |
Family ID | 43525726 |
Filed Date | 2011-02-03 |
United States Patent
Application |
20110023609 |
Kind Code |
A1 |
Ume; Ifeanyi Charles ; et
al. |
February 3, 2011 |
METHODS AND SYSTEMS FOR DETECTING DEFECTS IN WELDED STRUCTURES
UTILIZING PATTERN MATCHING
Abstract
A method for processing ultrasonic response signals collected
from a plurality of measurement locations along a weld to determine
the presence of a defect in the weld may include filtering an
ultrasonic response signal from each of the measurement locations
to produce a filtered response signal for each of the measurement
locations. Thereafter, an ultrasonic energy for each of the
measurement locations is calculated with the corresponding filtered
response signal. The ultrasonic energy for each measurement
location is then compared to the ultrasonic energy of adjacent
measurement locations to identify potential defect locations. When
the ultrasonic energy of a measurement location is less than the
ultrasonic energy of the adjacent measurement locations, the
measurement location is a potential defect location. The presence
of a defect in the weld is then determined by analyzing
fluctuations in the ultrasonic energy at measurement locations
neighboring the potential defect locations.
Inventors: |
Ume; Ifeanyi Charles;
(Atlanta, GA) ; Li; Renfu; (Johnes Creek, GA)
; Rogge; Matthew; (Atlanta, GA) ; Wu;
Tsun-Yen; (Atlanta, GA) |
Correspondence
Address: |
DINSMORE & SHOHL LLP
1900 CHEMED CENTER, 255 EAST FIFTH STREET
CINCINNATI
OH
45202
US
|
Assignee: |
GEORGIA TECH RESEARCH
CORPORATION
Atlanta
GA
|
Family ID: |
43525726 |
Appl. No.: |
12/534296 |
Filed: |
August 3, 2009 |
Current U.S.
Class: |
73/600 ;
73/579 |
Current CPC
Class: |
G01N 2291/2694 20130101;
G01N 29/449 20130101; G01N 29/11 20130101; G01N 2291/2675 20130101;
G01N 2291/0258 20130101 |
Class at
Publication: |
73/600 ;
73/579 |
International
Class: |
G01N 29/11 20060101
G01N029/11 |
Claims
1. A method for determining if a defect is present in a weld from
ultrasonic response signals collected from a plurality of
measurement locations along a weld, the method comprising:
filtering an ultrasonic response signal from each of the
measurement locations to produce a filtered response signal for
each of the measurement locations; calculating an ultrasonic energy
for each of the measurement locations with the corresponding
filtered response signal; comparing the ultrasonic energy for each
measurement location to the ultrasonic energy of adjacent
measurement locations to identify potential defect locations,
wherein, when the ultrasonic energy of a measurement location is
less than the ultrasonic energy of the adjacent measurement
locations, the measurement location is a potential defect location;
and analyzing fluctuations in the ultrasonic energy at measurement
locations neighboring the potential defect locations to determine
if a defect is present in the weld.
2. The method of claim 1 wherein the ultrasonic response signal
from each of the measurement locations is filtered by: decomposing
the ultrasonic response signal by discrete wavelet transform to
produce a set of wavelet coefficients for the ultrasonic response
signal; band-pass filtering the set of wavelet coefficients to
isolate a frequency range sensitive to defects in the weld; and
producing the filtered response signal for the measurement location
by performing inverse discrete wavelet transform on the
corresponding filtered set of wavelet coefficients.
3. The method of claim 1 wherein fluctuations in the ultrasonic
energy are analyzed by comparing the ultrasonic energy of a
potential defect location to the ultrasonic energy of a plurality
of measurement locations on each side of the potential defect
location, wherein, when the ultrasonic energy increases
monotonically over the plurality of measurement locations on each
side of the potential defect location, the potential defect
location comprises a defect.
4. The method of claim 3 wherein, when the potential defect
location comprises a defect, the ultrasonic energy of the potential
defect location and the ultrasonic energy of measurement locations
neighboring the potential defect location are compared to defect
energy patterns to determine what type of defect is present in the
weld.
5. The method of claim 1 wherein fluctuations in the ultrasonic
energy are analyzed by comparing the ultrasonic energy of a
potential defect location and the ultrasonic energy of measurement
locations neighboring the potential defect location to defect
energy patterns to determine if the potential defect location
comprises a defect.
6. A method for testing a weld for defects, the method comprising:
inducing ultrasonic signals at multiple measurement locations along
the weld; collecting an ultrasonic response signal for each of the
measurement locations; filtering the ultrasonic response signal
from each of the measurement locations to produce a filtered
response signal for each of the measurement locations; calculating
an ultrasonic energy for each of the measurement locations with the
corresponding filtered response signal; determining an ultrasonic
energy distribution for the weld based on the ultrasonic energy for
each of the measurement locations; identifying local minima in the
ultrasonic energy distribution; and analyzing fluctuations in the
ultrasonic energy distribution around each local minimum to
determine if a defect is present in the weld.
7. The method of claim 6 wherein the ultrasonic response signal
from each of the measurement locations is filtered by: decomposing
the ultrasonic response signal by discrete wavelet transform to
produce a set of wavelet coefficients for the ultrasonic response
signal; band-pass filtering the set of wavelet coefficients to
isolate a frequency range sensitive to defects in the weld; and
producing the filtered response signal for a measurement location
by performing inverse discrete wavelet transform on the filtered
set of wavelet coefficients.
8. The method of claim 6 wherein fluctuations in the ultrasonic
energy distribution around a local minimum are analyzed by
comparing the ultrasonic energy of the local minimum to the
ultrasonic energy of a plurality of measurement locations on each
side of the local minimum, wherein, when the ultrasonic energy
distribution increases monotonically at the plurality of
measurement locations on each side of the local minimum, the local
minimum is a defect location.
9. The method of claim 8 wherein, when the local minimum is a
defect location, the ultrasonic energy of the local minimum and the
ultrasonic energy of measurement locations neighboring the local
minimum are compared to defect energy patterns to determine what
type of defect is present in the weld.
10. The method of claim 6 wherein fluctuations in the ultrasonic
energy distribution are analyzed by comparing the ultrasonic energy
of a local minimum and the ultrasonic energy of measurement
locations neighboring the local minimum to defect energy patterns
to determine if a defect is present in the weld at the local
minimum.
11. The method of claim 6 wherein the ultrasonic response signal
for each measurement location is filtered to isolate a frequency
range from about 0.977 MHz to about 1.464 MHz.
12. The method of claim 6 wherein ultrasonic signals are induced by
directing an output beam of a pulsed laser source on to a surface
of a test sample in which the weld is located.
13. The method of claim 6 wherein: a plurality of ultrasonic
signals are induced in the weld at each of the measurement
locations; and a plurality of ultrasonic response signals are
collected at each of the measurement locations and averaged.
14. A defect detection system for identifying defects in a weld,
the defect detection system comprising a controller, an acoustic
signal generator, an acoustic signal detector, and a positioning
device, wherein the acoustic signal generator, the acoustic signal
detector and the positioning device are electrically coupled to the
controller and the controller is programmed to: induce ultrasonic
signals at multiple measurement locations along the weld with the
acoustic signal generator; collect an ultrasonic response signal
from each of the measurement locations with the acoustic signal
detector and store each ultrasonic response signal in a memory
operatively associated with the controller; filter the ultrasonic
response signal from each of the measurement locations to produce a
filtered response signal for the corresponding measurement
locations; calculate an ultrasonic energy for each of the
measurement locations with the corresponding filtered response
signal; compare the ultrasonic energy for each measurement location
to the ultrasonic energy of adjacent measurement locations to
identify potential defect locations, wherein, when the ultrasonic
energy of a measurement location is less than the ultrasonic energy
of the adjacent measurement locations, the measurement location is
a potential defect location; and analyze fluctuations in the
ultrasonic energy at measurement locations neighboring the
potential defect locations to determine if a defect is present in
the weld.
15. The defect detection system of claim 14 wherein the controller
is programmed to filter the ultrasonic response signal from each of
the measurement locations by: decomposing the ultrasonic response
signal by discrete wavelet transform to produce a set of wavelet
coefficients for the ultrasonic response signal; band-pass
filtering the set of wavelet coefficients to isolate a frequency
range sensitive to defects in the weld; and producing the filtered
response signal for the measurement location by performing inverse
discrete wavelet transform on the filtered set of wavelet
coefficients.
16. The defect detection system of claim 14 wherein the controller
is programmed to analyze fluctuations in the ultrasonic energy by
comparing the ultrasonic energy of a potential defect location to
the ultrasonic energy of a plurality of measurement locations on
each side of the potential defect location, wherein, when the
ultrasonic energy increases monotonically over the plurality of
measurement locations on each side of the potential defect
location, the potential defect location comprises a defect.
17. The defect detection system of claim 16 wherein, when the
potential defect location comprises a defect, the controller is
programmed to compare the ultrasonic energy of the potential defect
location and the ultrasonic energy of measurement locations
neighboring the potential defect location to defect energy patterns
to determine what type of defect is present in the weld.
18. The defect detection system of claim 14 wherein the controller
is programmed to analyze fluctuations in the ultrasonic energy by
comparing the ultrasonic energy of a potential defect location and
the ultrasonic energy of measurement locations neighboring the
potential defect location to defect energy patterns to determine if
the potential defect location comprises a defect.
19. The defect detection system of claim 14 wherein the acoustic
signal generator is a pulsed laser source.
20. The defect detection system of claim 14 wherein the acoustic
signal detector is an EMAT sensor.
Description
TECHNICAL FIELD
[0001] The present specification generally relates to methods and
systems for detecting defects in welded structures and, more
specifically, to methods and systems for detecting defects in
welded structures utilizing ultrasonic inspection in conjunction
with defect pattern matching.
BACKGROUND
[0002] Various welding techniques are commonly utilized to join
metallic parts to produce a wide variety of articles of manufacture
such as, for example, automobile components, aircraft components,
heavy equipment and machinery. The quality of the weld may play an
important role in the structural integrity of the welded structure
in which it is employed. However, during the welding or joining
operation, defects may be introduced or formed in the weld. Such
defects may include blowholes, voids, porosity and insufficient
weld penetration depth. Each of these defects may decrease the load
bearing capacity of the welded structure. For example, some types
of defects may act as stress risers or stress concentrators which
may impact the static, dynamic and fatigue strength of the weld and
the welded structure. Therefore, it is important to accurately
detect and locate potential defects in the welds.
[0003] When welds are formed automatically, such as by an automated
or robotic welding system, the quality of a weld may be assessed by
destructively testing a random sampling of the welded structures
that are produced. Destructive tests, such as cut-checks, may be
time-consuming and may generate excess product waste. Moreover,
automation of such destructive testing methodologies may not be
possible.
[0004] Efforts have been made to develop various non-destructive
testing techniques for detecting defects in welds. However, most of
these techniques may not be easily incorporated into manufacturing
environments.
[0005] Accordingly, a need exists for alternative methods and
systems for detecting defects in welds.
SUMMARY
[0006] In one embodiment, a method for processing ultrasonic
response signals collected from a plurality of measurement
locations along a weld to determine the presence of defects in the
weld may include filtering an ultrasonic response signal from each
of the measurement locations to produce a filtered response signal
for each of the measurement locations. Thereafter, an ultrasonic
energy for each of the measurement locations may be calculated with
the corresponding filtered response signal. The ultrasonic energy
for each measurement location may then be compared to the
ultrasonic energy of adjacent measurement locations to identify
potential defect locations. When the ultrasonic energy of a
measurement location is less than the ultrasonic energy of the
adjacent measurement locations, the measurement location is a
potential defect location. The presence of a defect in the weld may
then be determined by analyzing fluctuations in the ultrasonic
energy at measurement locations neighboring the potential defect
locations.
[0007] In another embodiment, a method for testing a weld for the
presence of defects may include inducing ultrasonic signals at
multiple measurement locations along the weld and collecting a
corresponding ultrasonic response signal for each of the
measurement locations along the weld. Thereafter, an ultrasonic
response signal from each of the measurement locations may be
filtered to produce a filtered response signal for each of the
measurement locations. An ultrasonic energy for each of the
measurement locations may then be calculated using the filtered
response signal for the corresponding measurement location.
Thereafter, an ultrasonic energy distribution for the weld may be
determined based on the calculated ultrasonic energy for each of
the measurement locations. Local minima in the ultrasonic energy
distribution may then be determined and fluctuations in the
ultrasonic energy distribution around each local minimum may be
analyzed to determine the presence of a defect in the weld.
[0008] In yet another embodiment, a defect detection system for
determining the presence of defects in a weld may include a
controller, an acoustic signal generator, an acoustic signal
detector, and a positioning device. The acoustic signal generator,
the acoustic signal detector and the positioning device may be
electrically coupled to the controller. The controller may be
programmed to: induce ultrasonic signals at multiple measurement
locations along the weld with the acoustic signal generator;
collect an ultrasonic response signal from each of the measurement
locations with the acoustic signal detector and store the
ultrasonic response signals in a memory operatively associated with
the controller; filter an ultrasonic response signal from each of
the measurement locations to produce a filtered response signal for
the corresponding measurement locations; calculate an ultrasonic
energy for each of the measurement locations with the corresponding
filtered response signal; compare the ultrasonic energy for each
measurement location to the ultrasonic energy of adjacent
measurement locations to identify potential defect locations,
wherein, when the ultrasonic energy of a measurement location is
less than the ultrasonic energy of the adjacent measurement
locations, the measurement location is a potential defect location;
and determine the presence of a defect in the weld by analyzing
fluctuations in the ultrasonic energy at measurement locations
neighboring the potential defect locations.
[0009] These and additional features provided by the embodiments
described herein will be more fully understood in view of the
following detailed description, in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The embodiments set forth in the drawings are illustrative
and exemplary in nature and not intended to limit the subject
matter defined by the claims. The following detailed description of
the illustrative embodiments can be understood when read in
conjunction with the following drawings, where like structure is
indicated with like reference numerals and in which:
[0011] FIG. 1 is a block diagram of a defect detection system
according to one or more embodiments shown and described
herein;
[0012] FIG. 2 depicts a defect detection system according to one or
more embodiments shown and described herein;
[0013] FIG. 3 depicts a test sample comprising a plurality of welds
and various manufacturing features;
[0014] FIG. 4 depicts a cross section of a weld of the test sample
of FIG. 3 illustrating various defects that may be present in the
weld;
[0015] FIG. 5 is a flow diagram of a method for detecting defects
in a welded structure according to one or more embodiments shown
and described herein;
[0016] FIG. 6 is a plot of an ultrasonic response signal collected
from a test sample according to one or more embodiments shown and
described herein;
[0017] FIG. 7 is a plot of an energy distribution derived from the
ultrasonic response signal of FIG. 6;
[0018] FIGS. 8A-8J schematically depict defect energy patterns
which may be used to identify the presence of defects in a weld by
comparison to an energy distribution, such as the energy
distribution of FIG. 7, according to one or more embodiments shown
and described herein; and
[0019] FIG. 9 is a plot of the energy distribution of FIG. 7 with
potential defect locations identified.
DETAILED DESCRIPTION
[0020] FIG. 1 generally depicts one embodiment of a defect
detection system for determining the presence and location of
defects in a weld. The system may generally comprise an acoustic
signal generator and an acoustic signal detector coupled to a
controller. The various components of the defect detection system
and methods of using the defect detection system to determine the
presence and location of defects in a welded structure will be
described in more detail herein.
[0021] Referring now to FIG. 1, a block diagram of a defect
detection system 100 is depicted. The defect detection system 100
may generally comprise an acoustic signal generator 104, an
acoustic signal detector 106 and a sample stage 108, each of which
are electrically coupled to a controller 102. Accordingly, it
should be understood that the solid lines and arrows shown in FIG.
1 are generally indicative of the electrical interconnectivity of
the various components of the defect detection system 100. It
should also be understood that the solid lines and arrows are
indicative of electronic signals, such as control signals and/or
data signals, propagated between the various components of the
defect detection system 100. Further, it should be understood that
the dashed line and arrow between the acoustic signal generator 104
and the test sample 110 is indicative of excitation signals 112
transmitted from the acoustic signal generator 104 to a test sample
110 while the dashed line and arrow between the test sample 110 and
the acoustic signal detector 106 is indicative of an ultrasonic
response signal 114 emitted from the test sample 110 due to the
received excitation signal 112 from the acoustic signal generator
104.
[0022] In the embodiments shown and described herein the acoustic
signal generator 104 may be a device operable to excite an
ultrasonic signal in the test sample 110 without physically
contacting the test sample. In one embodiment, the acoustic signal
generator 104 may comprise a pulsed laser source operable to excite
an ultrasonic signal in the test sample 110 by directing a series
of laser pulses onto the surface of the test sample. In another
embodiment, the acoustic signal generator 104 may comprise an
electromagnetic acoustic transducer (EMAT) operable to excite an
ultrasonic signal in the test sample 110 using electromagnetic
fields. It should be understood that the acoustic signal generator
104 may comprise other devices suitable for generating ultrasonic
signals in the test sample 110.
[0023] The acoustic signal detector 106 may generally be a device
operable to sense or detect the ultrasonic response signals 114
generated in the test sample 110 without physically contacting the
test sample. Accordingly, in one embodiment, the acoustic signal
detector 106 may comprise an EMAT sensor operable to detect the
acoustic response signal generated in the test sample 110. However,
it should be understood that various other non-contact transducers
and/or acoustic sensors may be used to detect the ultrasonic
response signal 114.
[0024] In one embodiment (not shown), where the acoustic signal
generator is an EMAT, the EMAT may be used to both excite an
ultrasonic signal in the test sample and to detect the ultrasonic
response signal from the test sample. Accordingly, it should be
understood that a single EMAT may be used as both the acoustic
signal generator and the acoustic signal detector.
[0025] In the embodiment of the defect detection system 100 shown
in FIG. 1, the sample stage 108 may comprise a fixture (not shown)
for mounting a test sample to the sample stage. The sample stage
108 may comprise one or more actuators (not shown), such as motors
and/or stepper motors, mechanically coupled to the stage and
electrically coupled to the controller 102. The controller 102, in
conjunction with the actuators, may be operable to adjust the
position of sample stage 108 and test sample 110 relative to the
acoustic signal generator 104 and acoustic signal detector 106 such
that the excitation signals 112 emitted by the signal generator may
be scanned over the test sample 110 in a controlled manner.
[0026] While the embodiments shown and described herein depict the
test sample as being fixtured to a moveable sample stage, it should
be understood that, in other embodiments (not shown), the acoustic
signal generator and the acoustic signal detector may be attached
to a moveable stage or similar positioning device electrically
coupled to the controller such that the acoustic signal generator
and the acoustic signal detector may be adjustably positioned
relative to the test sample. Accordingly, it should be understood
that the defect detection device may include at least one
positioning device for adjusting the relative orientation between
the test sample and the acoustic signal generator and acoustic
signal detector.
[0027] The controller 102 may comprise a computer operable to
execute a programmed instruction set and transmit control signals
to each of the components of the defect detection system 100. The
controller 102 may also be operable to store data received from the
acoustic signal detector 106 and analyze the stored data to
determine the presence of defects in a weld. Accordingly, it should
be understood that the controller 102 may comprise or be coupled to
one or more memory devices (not shown) for storing the programmed
instruction set and/or data received from the acoustic signal
detector. The controller 102 may also be coupled to one or more
audible or visual indicators, such as a display (not shown), for
providing a user with a visual or audible indication of the
presence and location of defects in the test sample and/or an
indication of whether the test sample has passed inspection.
[0028] Referring now to FIG. 2, one embodiment of a defect
detection system 150 is illustrated. In this embodiment the
acoustic signal generator is a pulsed laser source 105, such as an
Inlite II-20 Nd:YAG pulsed laser manufactured by Continuum Lasers.
The pulsed laser source 105 may have a 20 Hz pulse repetition rate
and a pulse width of 10 ns. The spot size of the laser may be about
6 mm and each pulse may have an energy from about 55 mJ to about
450 mJ. The acoustic signal detector may be an EMAT sensor 107. In
the embodiment depicted in FIG. 2 the EMAT sensor 107 is
manufactured by BWXT Services, Inc. and comprises a four channel
broadband receiver having a bandwidth from about 200 kHz to about
2.5 MHz. The EMAT sensor 107 may be coupled to the controller (not
shown) with a data acquisition card, such as, for example, a
Compuscope 8349 4 channel data acquisition card manufactured by
GaGe Applied Technologies which has 14 bit resolution and a data
sampling rate of 125 MHz. The sample stage 108 may include one or
more fixturing device(s) 109, such as clamps, vices, etc. for
holding test sample 110. The fixturing device and/or test sample
may include one or more datums (not shown) such that test samples
may be positioned on the sample stage with substantially the same
orientation relative to the pulsed laser source 105 and the EMAT
sensor 107. The sample stage 108 may be mounted to a stepper
motor-driven lead screw 122 coupled to the controller such that the
position of the sample stage may be adjusted with the
controller.
[0029] In the embodiment of the defect detection system 150 shown
in FIG. 2, the excitation source is the output beam 113 of the
pulsed laser source 105 which is optically coupled to the test
sample 110 with one or more mirrors. As depicted in FIG. 2, mirrors
116, 117 and 118 form an optical path between the output of the
pulsed laser source 105 and the surface of the test sample 110
which directs the output beam 113 onto the surface of the test
sample at the desired location. A lens 120 may be disposed in the
optical path of the output beam 113 to focus the output beam.
Additional optical elements (not shown) may also be inserted in the
optical path such as, for example, collimators or other elements
which may be used to shape the output beam 113 of the pulsed laser
source 105. Further, while the embodiments of the defect detection
system 150 shown in FIG. 2 depict the output beam 113 coupled to
the test sample 110 with mirrors, it should be understood that the
output beam may be directly coupled to the test sample without
being first diverted or reflected by a mirror. In alternative
embodiments (not shown), the output beam 113 of the pulsed laser
source may be coupled to the test sample with one or more optical
waveguides, such as an optical fiber or similar optical waveguides
capable of guiding a laser beam.
[0030] As described herein, the pulsed laser source may be used to
induce an ultrasonic signal in the test sample. Depending on the
energy density or power of the output beam pulse incident on the
surface of the test sample, the pulsed-laser source may be utilized
to create an ultrasonic signal in either a thermoelastic mode of
operation or an ablative mode of operation. For example, the
thermoelastic mode of ultrasonic signal generation occurs when the
power density of the output beam of the pulsed laser source is
relatively low. The output beam rapidly heats a localized area on
the surface of the test sample to a temperature less than the
melting point of the material due to partial absorption of the
laser radiation. The rapid increase in temperature is accompanied
by a corresponding expansion of the heated material due to
thermoelastic effects. The rapid expansion causes axis-symmetric
tensile stresses to develop in the surface of the test sample. When
the laser is switched off (e.g., between pulses), the heated region
contracts. The expansion and contraction of the top surface of the
test sample induces ultrasonic signals that propagate through the
test sample.
[0031] Alternatively, the ablative mode of ultrasonic signal
generation occurs when the power density of the output beam is high
enough to heat the surface of the test sample to above the melting
temperature of the material. The rapid heating creates
axis-symmetric tensile stresses in the surface of the test sample,
as described above. However, as the temperature on the surface of
the sample exceeds the melting temperature, a small amount of
material is vaporized and ejected from the surface of the test
sample. Accordingly, in addition to the formation of tensile
stresses, a normal reaction force is created against the surface of
the sample as the material is ejected. The combination of the
normal reaction force and the expansion and contraction of the top
surface induces ultrasonic signals that propagate through the test
sample. In general, ultrasonic signals generated through the
ablative mode are generally stronger that those generated in the
thermoelastic mode. In either mode of operation the ultrasonic
signals induced in the test sample have frequency content from
about 200 kHz to about MHz.
[0032] Referring now to FIGS. 2 and 3, the test sample 110 may
generally comprise a metallic structure which comprises at least
one weld 140. In the embodiment of the test sample 110 shown in
FIGS. 2 and 3, the test sample 110 is a structural support member
for an automobile which comprises an upper portion 142 and a lower
portion 143, both of which are formed from thin plates of stamped
sheet metal. The upper portion 142 may be joined to the lower
portion 143 at a lap joint (e.g., the joint shown in FIG. 4) with
welds 140. The test sample 110 may also comprise a plurality of
manufacturing features including, for example, press marks 144
resulting from a stamping operation and various attachment holes
146 for connecting components to the structural support member.
[0033] Referring now to FIG. 4 which depicts a cross section of a
lap joint and weld 140 between the upper portions 142 and lower
portion 143 of the test sample 110 of FIGS. 2 and 3, the weld 140
may contain one or more different types of defects including, for
example, blowholes, insufficient leg length (i.e., short legs),
insufficient penetration depth and/or insufficient throat thickness
(i.e., short throat). A blowhole defect occurs in the weld when air
or gas trapped in the weld escapes from the weld as the weld is
formed or as the weld cools. The escaping air or gas leaves a void
in the weld and/or forms pores in the weld, each of which may
decrease the strength of the weld.
[0034] The penetration depth of a weld is defined as the distance
PD which the fusion portion of the weld penetrates into the base
material, such as, for example, the upper portion 142 of the test
sample 110. If the penetration depth is less than a specified
percentage of the thickness of the base material an insufficient
penetration depth or lack-of-penetration defect occurs. In the
embodiments described herein, a lack-of-penetration defect occurs
when the distance PD is less than about 30% of the thickness of the
upper portion 142 of the test sample. However, it should be
understood that the specified percentage may be greater than 30% or
less than 30% depending on the application in which the test sample
110 is employed.
[0035] The legs of a lap joint weld 140 are defined as the distance
between the root 141 of the weld 140 and the toe of the weld (e.g.,
the point where the weld intersects the base material). The legs of
the weld 140 in FIG. 4 are shown as the distances S1 and S2. In the
embodiments described herein, a short leg defect is present in the
weld if either of the distances S1 or S2 is less than 80% of the
material thickness of either the upper portion 142 or lower portion
143 of the test sample 110. However, it should be understood that
the specified percentage may be greater than 80% or less than 80%
depending on the application in which the test sample 110 is
employed.
[0036] The throat thickness TH is defined as the shortest distance
between the root 141 ofthe weld 140 and the surface of the weld, as
shown in FIG. 4. A short throat defect occurs when the throat
thickness of the weld 140 is less than a specified percentage of
the thickness of the base material. In the embodiments shown and
described herein, a short throat occurs when the throat thickness
TH is less than about 70% of the thickness of either the upper
portion 142 or lower portion 143 of the test sample. However, it
should be understood that the specified percentage may be greater
than 70% or less than 70% depending on the application in which the
test sample 110 is employed.
[0037] Ultrasonic signals induced in the thin plates which comprise
the upper portion 142 and the lower portion 143 of the test sample
110 by operating the pulsed laser source in either the
thermoelastic mode or ablative mode produce a series of ultrasonic
Lamb waves which propagate through the test sample. The Lamb waves
may be multi-modal with each mode defined by a set of frequency and
wavelength pairs. Due to the different frequencies and wavelengths,
each mode of the Lamb wave may react differently to different types
of defects encountered in the test sample. For example, for a given
type of defect, a first mode defined by a first set of frequency
and wavelength pairs may be reflected by the defect while a second
mode having a second set of frequency and wavelength pairs may be
transmitted through the defect (i.e., the defect does not affect
the second mode). Accordingly, different modes of the induced Lamb
waves may be sensitive to different types of defects and, by
collecting and analyzing an ultrasonic response signal from the
test sample, the presence of different types of defects in the test
sample may be determined, as will be described in more detail
herein.
[0038] Referring now to FIG. 2, in order to determine the presence
of defects in a weld on a test sample, the test sample 110 may be
positioned on the sample stage 108 and attached to the sample stage
108 with one or more fixturing devices 109. The pulsed laser source
105 and EMAT sensor 107 may be positioned such that the EMAT sensor
107 collects an acoustic response signal either transmitted through
the weld or reflected by the weld.
[0039] For example, in one embodiment, when an acoustic response
signal transmitted through the weld is desired, the test sample 110
may be positioned such that the output beam of the pulsed-laser
source is incident on one side of the weld 140 and the EMAT sensor
107 is positioned on the other side of the weld 140 and adjacent to
the test sample 110, as shown in FIG. 2. Accordingly, it should be
understood that the weld 140 is positioned between the point where
the output beam 113 of the pulsed laser source 105 contacts the
test sample 110 and the EMAT sensor 107. In this embodiment, the
ultrasonic signals induced in the test sample 110 and received by
the EMAT sensor 107 are transmitted through the weld 140. As
defects alter the ultrasonic signal propagating through the weld
the ultrasonic signal is transformed to an ultrasonic response
signal which is received by the EMAT sensor 107. The ultrasonic
response signal carries with it information concerning the presence
of defects in the weld 140. Further, the ultrasonic response
signal(s) may be correlated to a position along the length of weld
140 and test sample 110 based on the relative positioning between
the test sample 110 and the point where the output beam of the
pulsed laser source contacts the test sample 110 and/or the
position of the EMAT sensor 107.
[0040] In another embodiment (not shown),when an acoustic response
signal reflected by the weld is desired, the EMAT sensor may be
positioned on one side of the weld and the output beam of the
pulsed-laser source may be directed onto the test sample on the
same side of the weld as the EMAT sensor. The ultrasonic response
signal induced in the test sample by the pulsed-laser source
propagates through the test sample to the weld which reflects at
least a portion of the signal (e.g., the ultrasonic response
signal), which is detected by the EMAT sensor. Because portions of
the weld which contain defects reflect or transmit the ultrasonic
signal differently than portions of the weld without defects, the
reflected ultrasonic response signal received by the EMAT sensor
carries with it information concerning the presence of defects in
the weld.
[0041] Referring now to FIGS. 2 and 5-9, one embodiment of a method
200 for detecting the presence of defects in a weld with the defect
detection system 150 is depicted. In a first step 202, the
controller triggers the pulsed laser source 105 to induce an
ultrasonic signal in the test sample 110 by directing a series of
beam pulses onto the surface of the test sample, as described
above. The controller may be programmed to trigger the pulsed laser
source multiple times at each measurement location and the
collected ultrasonic response signals generated by each firing of
the pulsed laser at each measurement location may be averaged to
increase the signal to noise ratio of the collected ultrasonic
response signal at that location. In the embodiments described
herein the pulsed laser source is operated in an ablative mode to
induce ultrasonic response signals in the test sample which have
frequency content from about 200 kHz to about 15 MHz. However, it
should be understood that the pulsed laser source may also be
operated in a thermoelastic mode to generate ultrasonic signals in
the test sample. The ultrasonic signal propagates through the test
sample 110 and the weld 140 and portions of the ultrasonic signal
may be reflected by defects in the weld 140 or other features in
the test sample while other portions of the ultrasonic response
signal may be transmitted through the weld 140. In this example,
the ultrasonic response signal is the signal transmitted or
reflected after portions of the ultrasonic signal are reflected
and/or defracted by defects and/or other features in the test
sample.
[0042] In a second step 204, the ultrasonic response signal induced
in the test sample 110 is collected with the EMAT sensor 107. In
the embodiments described herein, the EMAT sensor 107 is positioned
to collect an ultrasonic response signal which is transmitted
through the weld 140, as illustrated in FIG. 2 and described above.
The EMAT sensor 107 converts the collected ultrasonic response
signal to an electrical signal which has a voltage proportional to
the amplitude of the ultrasonic response signal. Accordingly, in
the embodiments described herein where the collected ultrasonic
response signal has been transmitted through the weld 140,
electrical signals produced by the EMAT sensor 107 with relatively
large voltages correspond to ultrasonic response signals with
relatively greater amplitudes while electrical signals with
relatively low voltages correspond to ultrasonic response signals
with relatively lower amplitudes. The relative magnitude of the
ultrasonic response signal may be generally indicative of the
absence or presence of defects and/or manufacturing features in the
test sample with lower amplitudes indicative of the presence of a
defect and/or manufacturing feature and higher amplitudes
indicative of the absence of a defect and/or manufacturing
feature.
[0043] The electrical signal produced by the EMAT sensor 107 is
transmitted from the EMAT sensor 107 to the controller (not shown)
where the electrical signal is stored in a memory associated with
the controller. The amplitude (i.e., the voltage) of the electrical
signal is stored in the memory as a function of time and indexed or
correlated to a specific position along the weld 140 of the test
sample 110. Accordingly, it should be understood that the amplitude
of the ultrasonic signal may be a function of both time (t) and
position (x) along the weld 140 and, as such, may be written as
f(x,t).
[0044] After the collected ultrasonic signal is stored in memory
for one measurement location along the weld 140, the position of
the test sample 110 relative to the pulsed laser source 105 and
EMAT sensor 107 may be adjusted such that ultrasonic sonic response
signals may be induced and collected from the test sample 110 at a
different measurement location along the weld 140. In the
embodiment shown in FIG. 2, the position of the test sample 110
relative to the pulsed laser source 105 and EMAT sensor 107 may be
adjusted by the controller which sends a control signal to the
stepper motor (not shown) coupled to the lead screw 122. Rotation
of the stepper motor causes the lead screw 122 to rotate, which, in
turn, imparts translational motion to the sample stage 108 thereby
adjusting the position of the test sample 110 relative to the
pulsed laser source 105 and EMAT sensor 107.
[0045] After the position of the test sample 110 has been adjusted,
steps 202 and 204 may be repeated at a new location along the weld
140 and the amplitude of the ultrasonic response signal is stored
in the memory operatively associated with the controller as a
function of both time (t) and location (x) along the weld. This
process of inducing an ultrasonic signal, collecting an ultrasonic
response signal and adjusting the position of the test sample may
be repeated multiple times to develop a set of ultrasonic response
signals for a segment of the weld and/or the entire length of the
weld 140. FIG. 6 graphically illustrates a set of ultrasonic
response signals collected from one test sample. The y-axis is
indicative of the position along the weld, the x-axis is indicative
of the time interval over which the ultrasonic response signal was
collected, and the gray scale is indicative of the relative
amplitude of the collected ultrasonic response signal in units of
voltage. The position of the test sample was adjusted in millimeter
increments although larger or smaller increments may be used
depending on the desired defect resolution.
[0046] Still referring to FIG. 6, the higher frequency/shorter
wavelength content of the ultrasonic signals induced in the test
sample may be more susceptible to diffraction and/or reflection by
features in the test sample than other, lower frequencies. These
features may include regular features (i.e., features regularly
occurring in each of a plurality test samples) such as
manufacturing features (e.g., connector holes, stamp marks, etc.)
and irregular features such as defects. For example, one frequency
range particularly susceptible to reflection and/or diffraction by
these features may be from about 0.977 MHz to about 1.464 MHz.
Accordingly, the corresponding frequencies in the ultrasonic
response signal collected from the test sample may contain
information regarding the presence of such features.
[0047] In step 206, the controller may be programmed to filter the
ultrasonic response signals collected from the test sample to
isolate frequencies most susceptible to reflection and/or
diffraction by features such as manufacturing features and/or
defects. In the embodiments described herein, the collected
ultrasonic response signals for each measurement location (x) along
the weld may be filtered into frequency ranges that are sensitive
to features (such as defects) in the test sample by first
decomposing the collected ultrasonic response signal by discrete
wavelet transform (DWT). Specifically, for a specified location x
along the weld, the collected ultrasonic response signal f(t) may
be decomposed into a set of wavelet coefficients WS(h,k) according
to the relationship:
WS(h,k)=.intg.f(t).PSI..sub.h,k*(t)dt (1),
where .PSI.*.sub.h,k(t) is the complex conjugate of wavelet
.PSI..sub.h,k(t). Wavelet .PSI..sub.h,k(t) may be a function of a
mother wavelet function .PSI. which is scaled by scaling parameter
s.sub.0.sup.h and shifted by shifting parameter
k.tau..sub.0s.sub.0.sup.h such that:
.PSI. h , k ( t ) = 1 s 0 h .PSI. ( t - k .tau. 0 s 0 h s 0 h ) , (
2 ) ##EQU00001##
where t is time and h and k are integers. s.sub.0 is generally
selected to be 2 and the shifting parameter .tau..sub.0 is
generally selected to be 1.
[0048] The selection of the mother wavelet .PSI. may depend on the
shape or form of the collected ultrasonic response signal as a
given ultrasonic response signal may be better approximated by a
wavelet having a shape or form similar to that of the signal. The
mother wavelet .PSI. used for decomposition of the ultrasonic
response signal may be selected from, for example, the Daubechies
wavelet family, the Coiflet wavelet family, the Haar wavelet
family, the Symmlet wavelet family, the Discrete Meyer (DMEY)
wavelet or similar wavelet families. For example, in one embodiment
wavelet 6 of the Daubechies wavelet family may be used as the
mother wavelet .PSI. to decompose the ultrasonic response signal.
However, it should be understood that other mother wavelets may be
used.
[0049] As indicated by Equation 1, decomposition of the ultrasonic
response signal for each measurement location x by DWT produces a
set of wavelet coefficients WS(h,k) for that measurement location.
After decomposition, the controller may be programmed to band-pass
filter each resulting set of wavelet coefficients to isolate a
frequency range most sensitive to defects which, in the embodiments
described herein, is from about 0.977 MHz to about 1.464 MHz.
Filtering the set of wavelet coefficients is performed by zeroing
elements of the wavelet coefficient WS(h,k) that correspond to
frequency content outside the desired frequency range. In the
embodiments described herein, decomposition by DWT and filtering
may be performed by the controller using Mallet's filter banks
algorithm which produces a band-pass filtered set of wavelet
coefficients for each measurement location along the weld.
[0050] After each collected ultrasonic response signal is
decomposed by DWT and the resulting wavelet coefficients are
filtered to isolate the desired frequency content, the controller
may be programmed to reconstruct a filtered response signal f(x,t)
for each measurement location from the corresponding filtered sets
of wavelet coefficients by inverse discrete wavelet transform
(IDWT) to form a filtered response signal for each measurement
location x along the weld. For example, when there are 120 separate
measurement locations along the weld, 120 filtered response signals
are created by IDWT.
[0051] In a next step 208, the controller may be programmed to
calculate and normalize an energy E(x) for each measurement
location x on the test sample based on the corresponding filtered
response signals f(x,t) for the measurement location. The energy
E(x) for each measurement location x may be calculated by summing
the square of the corresponding filtered response signal f(x,t)
over the time duration of the signal such that:
E ( x ) = t ( f ( x , t ) ) 2 , ( 3 ) ##EQU00002##
where E(x) is the energy at location x and f(x,t) is the amplitude
of the filtered ultrasonic response signal at location x and time
t.
[0052] Based on the energy E(x) for each measurement location along
the weld, an energy distribution may be plotted as depicted in FIG.
7 where the x-axis corresponds to the measurement location x along
the weld and the y-axis corresponds to the ultrasonic signal energy
E(x) for each measurement location. The plotted energy distribution
shows that the energy of the ultrasonic response signal fluctuates
along the length of the weld. These fluctuations in energy may be
caused by the presence of various features in the test sample
and/or weld which may reflect or diffract the ultrasonic signal
induced in the test sample. Such features may include regular
features, such as stamp marks, connector holes, and the like, or
irregular features, such as defects and/or changes in the thickness
of the weld, as described above.
[0053] Referring now to FIGS. 5, 7 and 9, in a next step 210, the
controller may be programmed to identify potential defect locations
along the weld utilizing the energy E(x) for each measurement
location and/or a plotted energy distribution, such as the plotted
energy distribution shown in FIG. 7. To identify potential defect
locations, the controller may compare the energy E(x) for each
measurement location x to the energy of adjacent measurement
locations, such as, for example, measurement locations x-1 and x+1.
If the energy E(x) is a local minimum (e.g., E(x-1)>E(x) and
E(x+1)>E(x)) then measurement location x is a potential defect
location. Examples of potential defect locations are indicated by
the circled points in the plotted energy distribution shown in FIG.
9. Where E(x) is a local minimum, the controller may designate the
position x of the local minimum as a potential defect location
x.sub.pd and stores the potential defect location x.sub.pd in a
memory operably associated with the controller.
[0054] Referring now to FIGS. 5 and 7-9, in a next step 212, the
controller may be programmed to analyze fluctuations in the
ultrasonic energy at measurement locations neighboring each
potential defect location x.sub.pd to determine the presence of
defects in the weld utilizing the energy E(x.sub.pd) of the
potential defect location x.sub.pd and the energy of neighboring
measurement locations. In one embodiment, the controller may
analyze each potential defect location x.sub.pd for the presence of
defects by comparing the energy E(x.sub.pd) of the potential defect
location and the energy of adjacent measurement locations to a set
of defect energy patterns, such as the exemplary defect energy
patterns graphically depicted in FIGS. 8A-8J, which may be stored
in the memory operatively associated with the controller.
[0055] The defect energy patterns shown in FIGS. 8A-8J may be
derived from test samples which have been destructively examined
after ultrasonic signals have been induced in the test samples and
ultrasonic response signals have been collected from the test
samples, as described above. An energy distribution for each test
sample may then be plotted and the results of the destructive
examination of each test sample may be compared to the
corresponding energy distribution to correlate fluctuations in the
energy distribution to the defects identified through destructive
examination. Based on these comparisons a set of defect energy
patterns may be identified which correspond to fluctuations in the
energy distribution caused by the defects. Further, the results of
the destructive examination may be used to correlate specific
defect energy patterns to specific defect types (e.g., short legs,
blow holes, lack of penetration, etc.).
[0056] In order to determine if a potential defect location
x.sub.pd contains an actual defect, the controller compares the
pattern formed by the energy E(x.sub.pd) of each potential defect
location x.sub.pd and the energy of neighboring measurement
locations on each side of the potential defect location x.sub.pd to
the defect energy patterns and, if the patterns have a similar
shape, the controller designates the potential defect location
x.sub.pd as a defect location x.sub.D and stores this location as a
defect location in the memory operatively associated with the
controller.
[0057] Referring to FIGS. 8 and 9 by way of example, a potential
defect location x.sub.pd is present at x=104 mm. The pattern formed
by the energy E(x.sub.pd) of this potential defect location and the
energy of measurement locations on each side of the potential
defect location (e.g., the 3 measurement locations to the left of
x=104 mm and the three measurement locations to the right of x=104
mm) form a pattern similar to the defect energy pattern of FIG. 8I
and, as such, the controller identifies the potential defect
location at x=104 mm as a defect location x.sub.D and stores this
location in memory as a defect.
[0058] In an alternative embodiment, at step 212, the controller
may be programmed to analyze each potential defect location
x.sub.pd by comparing the energy E(x) at each potential defect
location x.sub.pd to the energy of a plurality of neighboring
measurement locations. The controller may compare the energy for
potential defect location x.sub.pd to the energy for at least two
consecutive measurement locations on each side of the potential
defect location x.sub.pd. For example, the controller may compare
the energy for points x.sub.pd-1, x.sub.pd-2 . . . x.sub.pd-i on
one side of x.sub.pd, and to points x.sub.pd+1, x.sub.pd+2 . . .
x.sub.pd+j on the other side of x.sub.pd, where i and j are
integers, i<x.sub.pd and 1.ltoreq.j.ltoreq.n-x.sub.pd and n is
the total number of measurement locations along the weld.
[0059] If the ultrasonic energy on each side of the potential
defect location increases monotonically for each of the neighboring
measurement locations, and if the number of neighboring measurement
locations with monotonically increasing energy is between two and
four on each side of the defect location, then the controller
identifies the potential defect location x.sub.pd as a defect
location x.sub.D and stores the location in a memory operatively
associated with the controller. As shown in FIG. 9, locations
enclosed by a solid circle (e.g., at x=18 mm, 50 mm and 104 mm) are
indicative of defect locations and the locations enclosed by a
dashed circle (e.g., at x=70 mm and 88 mm) are potential defect
locations which, after further analysis by the controller, do not
meet the criteria for the presence of a defect (i.e., the
ultrasonic energy does not increase monotonically over at least two
neighboring measurement locations or it increases monotonically
over more than four neighboring measurement locations on each side
of the potential defect location).
[0060] In one embodiment, after the ultrasonic energy of the
potential defect location is compared to at least two neighboring
defect locations on each side of the potential defect location to
determine if the ultrasonic energy increases monotonically, the
energy of the potential defect location and the energy of
neighboring measurement locations may be compared to defect energy
patterns stored in memory, as described above, to further assess
whether the potential defect location contains a particular defect,
such as, for example, a lack of penetration defect which has a
defect energy pattern as shown in FIG. 8J. If the ultrasonic energy
at the potential defect location and the ultrasonic energy at the
neighboring defect locations corresponds to a defect energy
pattern, then the controller designates the potential defect
location x.sub.pd as a defect location x.sub.D and stores the
location in memory as a defect.
[0061] In one embodiment, in order to identify a lack of
penetration defect such as that shown in FIG. 8J, the controller
may be programmed to first identify local maximum and minimum pairs
by comparing the energy of each measurement location to the energy
of neighboring measurement locations. For example, the points
X.sub.N1 and X.sub.N2 shown in FIG. 8J are indicative of local
maximum and minimum, respectively. Thereafter, the average slope
between the local maximum and minimum may be determined utilizing
the following equation:
slope avg = E ( X N 2 ) - E ( X N 1 ) X N 2 - X N 1 , ( 4 )
##EQU00003##
where E(X.sub.N2) is the energy at measurement location X.sub.N2
and E(X.sub.N1) is the energy at measurement location X.sub.N1.
[0062] Thereafter, for each point X.sub.i between X.sub.N1 and
X.sub.N2, the controller may be programmed to determine the slope
between points X.sub.i and X.sub.i-1 and the slope between points
X.sub.i and X.sub.i-1 and compare each slope to the averaged slope.
If the absolute value of the slope between points points X.sub.i
and X.sub.i-1 and the absolute value of the slope between points
X.sub.i and X.sub.i+1 are both greater than the average slope, then
the point X.sub.i is a defect location.
[0063] In yet another embodiment, at step 212, the controller may
be programmed to analyze each potential defect location x.sub.pd by
comparing the energy E(x) at each potential defect location
x.sub.pd to the energy of a plurality of neighboring measurement
locations, as described above. When the energy on each side of the
potential defect location increases monotonically for each of the
neighboring measurement locations, the controller identifies the
potential defect location x.sub.pd as a defect location x.sub.D and
stores the location in a memory operatively associated with the
controller. The controller may then be programmed to compare the
pattern formed by the energy E(x.sub.D) of each defect location
x.sub.D and the energies of neighboring measurement locations to
defect energy patterns stored in memory to identify the specific
types of defects which may be present in the weld.
[0064] In step 214, the controller may provide a visual and/or
audible indication of the presence of defects in the weld. In one
embodiment, where the defect detection system 150 comprises a
display, the controller may be programmed to plot an energy
distribution on the display similar to that shown in FIG. 7. The
controller may also be programmed to identify defect locations on
the display. For example, where the controller is programmed to
display a plot of the energy distribution on the display, the
controller may be programmed to graphically indicate the location
x.sub.D of defects on the energy distribution. Alternatively or
additionally, the controller may be programmed to display the
location of each defect. For example, referring to the plot of the
energy distribution shown in FIG. 9, the controller may be operable
to indicate on the display that defects are present in the weld at
x=18 mm, 50 mm and 104 mm.
[0065] It should now be understood that the defect detection system
and methods shown and described herein may be used to determine the
presence and location of defects in a weld utilizing ultrasonic
signals. The system may be implemented in a manufacturing
environment to perform automated inspection of welded structures of
various configurations. The system may be used as a quality control
tool for each welded structure produced or, alternatively, to
analyze a random sampling of the welded structures produced.
[0066] While the defect detection systems described herein utilize
non-contact methods for inducing an ultrasonic signal in the test
sample and collecting an ultrasonic response signal from the test
sample, it should be understood that the methods utilized by the
defect detection systems may also be used by ultrasonic inspection
systems which utilize acoustic signal generators and/or acoustic
signal detectors which physically contact the test sample.
[0067] Further, while the methods for analyzing the ultrasonic
response signals collected from the test sample are described
herein as being performed in conjunction with inducing an
ultrasonic signal in the test sample and collecting ultrasonic
response signals from the test sample, it should be understood that
the method for analyzing the ultrasonic response signals may be
performed independently from the steps of inducing an ultrasonic
signal and collecting an ultrasonic response signal. For example,
the collected ultrasonic response signals may be stored in the
controller and analyzed according to the methods described herein
at a later time.
[0068] It is noted that the terms "substantially" and "about" may
be utilized herein to represent the inherent degree of uncertainty
that may be attributed to any quantitative comparison, value,
measurement, or other representation. These terms are also utilized
herein to represent the degree by which a quantitative
representation may vary from a stated reference without resulting
in a change in the basic function of the subject matter at
issue.
[0069] While particular embodiments have been illustrated and
described herein, it should be understood that various other
changes and modifications may be made without departing from the
spirit and scope of the claimed subject matter. Moreover, although
various aspects of the claimed subject matter have been described
herein, such aspects need not be utilized in combination. It is
therefore intended that the appended claims cover all such changes
and modifications that are within the scope of the claimed subject
matter.
* * * * *